Method for terminating leads of plural wires in dynamo electric machine core

ABSTRACT

Method and Apparatus are provided for automatically disposing plural wires along predetermined trajectories, wherein the plural wires extend from coils wound in slots of dynamoelectric machine cores. Plural wires forming leads are located in predetermined positions and caused to extend along predetermined directions by means of manipulating equipment and tooling which operates automatically. In addition, the equipment and tooling cause the plural wires to become twisted and cut to form portions for connection to terminals. The tooling is provided with reference surfaces and seats which are used to bend the plural wires along the predetermined trajectories and to provide a position constraint for the portions becoming twisted. Apparatus can be provided for positioning portions of a plurality of restraining members in the spacing existing between the bridges of the coils and the end faces of a dynamo electric machine core.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a division of U.S. patent application Ser. No. 12/312,088, filedApr. 24, 2009, now U.S. Pat. No. 8,468,686, as the United StatesNational Stage of International Patent Application No.PCT/EP2007/009561, filed Nov. 5, 2007, each of which is herebyincorporated herein by reference in its respective entirety.

BACKGROUND OF THE INVENTION

The present invention relates to methods and apparatus for terminatingleads of wire coils wound on magnetic cores of dynamo-electric machinecomponents, such as stators for electric motors or generators.

DESCRIPTION OF THE PRIOR ART

The wire coils may be formed by simultaneously winding plural wiresusing a nozzle winder having one or more wire dispensing needles thatdeliver the plural wires directly into the slots of the magnetic core.

Alternatively, the wire coils can be first wound on a winding form byusing a rotating flyer, or by rotating the winding form in order to drawonto the latter the plural wire. The finished wire coils are laterstripped from the winding form and placed onto a tool, which is used fortransfer to an insertion unit where a pushing operation inserts the wirecoils and insulation covering into the slots of the magnetic core.

Generally, the wire coils are formed from a predetermined number of wireturns, where each wire turn consists of coil branches formed from acertain number of wires. The exemplary winders according to theseprinciples are described, for example, in EP 1,076,401 and U.S. Pat. No.6,557,238

U.S. Pat. No. 6,141,864 proposes a winding tool that is applied to astator and which has slots for temporarily receiving leads to place themtogether and cut them. The cut leads are later removed from the slotsand connected together by twisting. The winding tool optimizes manualoperations of preparing the leads together and cutting them.

With modern stators, the number of leads of a core requiring the routingand mentioned termination procedures is increasing. Furthermore, thesize and number of the wires used to form the plural wires is alsoincreasing. Consequently, production times for the termination processesare becoming importantly longer and the automatic operations of theprocesses are becoming considerably more complex and difficult toachieve.

In view of the foregoing, it is an object of this invention to providemethods and apparatus for automatically placing the lead wires inrelation to the core and twisting certain portions of the same leadwires to form a required section size of plural wires. It is anotherobject of this invention to provide the above mentioned apparatus thatcan be readily adjusted to account for required variations in theplacement of the leads.

A further problem is that the finished magnetic cores need to beextremely compact without requiring additional components for supportingthe leads that have been routed proximal to the end faces of the core.To achieve this, the leads are routed directly in contact with thecoils, and from here can depart in predetermined directions to becometwisted.

It is therefore another object of this invention to provide methods andapparatus for automatically placing the lead wires in relation to thecore and twisting certain portions of the same lead wires to form arequired section size without requiring the use of additional componentsthat need to be permanently assembled on the finished core forsupporting the leads.

SUMMARY OF THE INVENTION

The invention foresees using termination members temporarily applied toat least one end of the magnetic core, after having wound the wire coilswith plural wires drawn simultaneously. Initially, the leads formed fromthe plural wires are drawn in predetermined positions around the core asa result of the winding procedures. Successively, a wire manipulatorselectively grasps the leads formed from the plural wires and moves themalong the end faces of the core. At certain locations, the manipulatordraws the plural wires within respective seats of the terminationmembers. When moving the plural wires with the manipulator, these can bedrawn against predetermined surfaces of the termination members so thatthe plural wires become deformed to follow predetermined configurationsthat correspond to the paths where the leads need to be permanentlypositioned adjacent to the ends of the coils.

Along the paths the plural wires can be passed through respective seatsof the termination members. In doing so, the plural wires can be made tochange direction so that they finally extend in predetermineddirections. The direction change occurs by bending the plural wiresagainst reference surfaces existing adjacent the entrance of the seat.Consequently, the plural wires forming a typical lead will exit the seatand extend beyond it in a predetermined direction. A portion of theplural wires extending in the predetermined direction can be twistedtogether for a certain length by programmed movements of themanipulator. The programmed movements of the manipulator are such thatthe plural wires become twisted together and pulled against thereference surfaces that are adjacent to the entrances of the seats. Eachseat maintains the plural wires in a predetermined position during thetwisting operations. Consequently, the resulting twisted portion will belocated in a predetermined position determined by the seat and extendsin the predetermined direction for a required length

A cutter can later cut the twisted portions at a predetermined lengthfrom the core in order to form accurate extremities for connection toterminals.

Twisting causes each wire to form a helix having turns that will beplaced adjacent and in contact with turns of the helixes formed with theother wires. The helixes of the various wires should be similar, i.e.their diameter and pitch should be the same so that crossing of thewires is avoided.

The wire termination tool may also include surfaces for pressing therouted leads against the coils to thereby limit the overall size of thefinished core.

Due to the high number of leads that can be present in the core, andalso for the complexity of the paths where the leads need to be placed,routing and twisting of the various leads can occur in various stages,which are performed in sequence to finish the core. More specifically,in each stage a limited number of finished leads of the total number ofleads can be routed and twisted by using specific wire terminationmembers. Accordingly, multiple termination apparatuses, each having wiremanipulators and specific wire termination members can process insuccession a given core to finish it. At the same time the multipleapparatuses can be working in parallel for performing respective stagesof the termination cycle on different cores in order to reduce theproduction time for a core, and thereby increase productivity.

For certain number of wires that need to be twisted, there can be a wirethat does not become twisted, which is located centrally amongst theplural wires. This wire can have less contact with the terminal becauseit becomes completely buried by the other wires. It is preferable toavoid that such a wire remains centrally and without twisting. In thissituation, a lower number of plural wires can be twisted together inorder to avoid that one wire remains centrally and without twisting. Thelower number of wires that are twisted together is such as to avoid thatone wire remains centrally and without twisting. Successively, thetwisted portions with the lower number of wires can be twisted togetherto achieve the final result of a final twisted portion that has all therequired wires.

Restraining members are placed in the free space of the bridges of thecoils to prevent the coil wires from moving towards the faces of thecore when the manipulator pulls on portions of the leads duringtwisting.

More particularly, the restraining members act as bearing surfaces forcoils in planes approximately parallel to the end faces of the core.

Consequently, the wires of a coil engage the bearing surfaces duringtwisting and prevent movement of the coil heads towards the faces of thecore. In this way a damaging contact is avoided between the coil headsand the slot insulating lining that protrudes beyond the end faces ofthe core. The final result is that the coil heads are impeded fromengaging and crushing, or tearing, the insulating lining of the slots.

The restraining members can simultaneously move on respective radiuseswith respect to the core, from an outward position that allows clearancefor loading and unloading of the core to an inward position where therestraining members carry out their function of support surfaces duringtwisting of the coil leads.

The restraining members and the members for moving the restrainingmembers in the radial directions can constitute a support assembly,which is mounted on a table. The table can have the purpose oftransferring and positioning of the cores at various working stationswhere routing and twisting of the leads need to be performed.

The core can be supported and referenced by the support assembly.

In turn, the support assembly can be referenced and supported by thetable.

The table can require various support positions for the cores.Consequently, a support assembly having the restraining members for acore can be mounted in each of the support positions of the table.

The actuator for moving the restraining members in the radial directionscan belong to an actuating unit that is external both to the supportassembly and the table. The actuator can cause movement of therestraining members when the support assembly becomes aligned with theactuating unit, as a result of movement of the table for transferringthe cores.

The restraining members may be used to support only the wires of thecoils heads that are adjacent to one face of the core. In this case,just the portions of one series of restraining members are positioned inthe free spacing of the coils heads adjacent to that face of the core.

When the support function is required for the coil heads adjacent toboth faces of the core, two series of restraining members are foreseen.More particularly, during twisting one series of restraining memberssupport the coils heads adjacent to one face of the core and a secondseries of restraining members support the coil heads adjacent to theother face of the core

The support assembly can be easily adapted for supporting cores ofdifferent height. The different height of a core requires aligning therestraining members with the different positions occupied by the freespacing existing between the coil heads.

The support assembly can easily be assembled on the table so thatsubstitution of a support assembly can occur rapidly.

Therefore according to another aspect of the invention an apparatus fortwisting plural wires comprises restraining members with portionspositioned in spacing of the bridges of the coils to resist movement ofthe coils towards a face of the core during twisting of the pluralwires; means for guiding the restraining members in the radial directionof the core to position the portions of the restraining members in thespacing of the bridges adjacent to an end face of the core;

means for moving the restraining members in the radial direction.According to another aspect of the invention, the apparatus comprisesmeans for rotating the means for moving the restraining members in orderto collectively move the restraining members in the radial directionwith a synchronized motion and means for supporting the means for movingand the means for rotating.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the method and apparatusaccording to the invention will be more apparent from the followingdetailed description and the accompanying drawings of the preferredembodiments, which is made to be exemplary without being limitative.

FIG. 1 is a perspective view of an illustrative embodiment of a statorat an intermediate stage of being manufactured in accordance with theprinciples of the invention

FIG. 2 is a perspective view of an embodiment of termination memberswhich can be used for manufacturing the stator shown in FIG. 1. In FIG.2 the termination members have been shown transparent for sake ofclarity. FIG. 2 also illustrates portions of leads formed from pluralwires routed and twisted in accordance with the principles of theinvention, although in FIG. 2 the stator has been omitted for sake ofclarity

FIG. 3 is a view from direction 3 of FIG. 2. In FIG. 3 the terminationmembers have been shown transparent for reasons of clarity. FIG. 3 alsoshows that the termination members can be assembled on the stator ofFIG. 1, which is shown with dashed line representation. Furthermore,FIG. 3 shows a manipulator in the process of routing a lead formed fromplural wires

FIG. 4 is a partial section view as seen from directions 4-4 of FIG. 3illustrating the termination members applied to the stator shown inFIGS. 1 and 3. For reasons of clarity, FIG. 4 shows the leads of FIGS. 2and 3 in their condition prior to twisting and without the manipulatorshown in FIG. 3.

FIG. 4 a is a partial section view as seen from directions 4 a-4 a ofFIG. 4.

FIG. 4 b is a partial section view as seen from directions 4 b-4 b ofFIG. 4

FIG. 4 c is a partial section as seen from a direction like 4 c of FIG.4 illustrating parts which have been omitted in FIG. 4, due to theinterruption made in FIG. 4 for reasons of clarity

FIG. 5 is a partial view from direction 5 of FIG. 4 illustrating stagesof routing a lead in accordance with the principles of the invention.

FIGS. 6-9 are partial views from direction 6 of FIG. 4, with certainparts omitted for sake of clarity, illustrating various stages ofrouting and forming a twisted portion of a lead in accordance with theprinciples of the invention.

FIG. 10-13 are views similar to FIGS. 5 and 6 illustrating differentstages of routing and forming a twisted portion of a lead in accordancewith the principles of the invention.

FIG. 14 is a view similar to FIG. 3 showing a manufacturing environmentwith multiple stations for terminating the core.

FIG. 15 is a plan view like the view of FIG. 14 illustrating a supportassembly for the core with restraining members positioned in an innerradial position, like is the condition for supporting coil heads duringtwisting operations. In FIG. 15 the core has been omitted for reasons ofclarity and the support assembly is assembled on a table, like the tableof FIG. 14 adopted for transferring and positioning of the core atvarious stations where twisting of the coil leads occurs.

FIG. 16 is a section view as seen from directions 216-216 of FIG. 15illustrating the support assembly of the invention for positioning therestraining members and supporting the cores.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1, 3 and 4 illustrate stator 10 wound with coils 11 and leads 12each consisting of plural wires W. The coils have been wound in slots13. The ends 14 of the coils extend beyond faces 15 of the core. In FIG.1 certain leads 12 have been drawn to predetermined radial positionsaround the stator core in preparation for routing along predeterminedpaths and termination into terminals in accordance with the principlesof the invention.

In FIGS. 1, 2 and 3 other leads 16 and 17 are already routed, twistedand cut in accordance with the principles of the invention

More particularly, twisted portion 16′ of lead 16 is upstanding indirection 33 with respect to the ends 14 of the coils due to bending atposition 18. Furthermore, twisted portion 16′ has been cut at apredetermined distance with respect to end face 15. (see also FIGS. 2and 3)

Similarly, twisted portion 17′ of lead 17 is upstanding in direction 34with respect to the ends 14 of the coils due to bending at position 19.Also twisted portion 17′ has been cut to a predetermined distance withrespect to end face 15 (see also FIGS. 2 and 3).

The diameter D of twisted portions 16′ and 17′ (see FIG. 2) needs to bewithin prescribed tolerances for correct joining to terminals.

FIG. 2 illustrates termination tool 21 consisting of two members 22 and23 without the presence of stator 10. FIGS. 3 and 4 illustrate members22 and 23 assembled on the stator, as is required for routing leads 16and 17 and for forming twisted portions 16′ and 17′.

More particularly, and with reference to FIG. 4, members 22 and 23 havebeen mounted coaxial to the axis 10′ of stator 10. This can beaccomplished by having abutment and centering of cylindrical shoulder 24of member 23 with face 15 and the hollow walls of the stator.

Member 22 is sleeved into the cylindrical cavity 25 of member 23. Inaddition, member 22 is referenced angularly around axis 10′ with respectto member 23 by a key engagement (not shown) existing between member 22and member 23. Similarly, member 23 is referenced angularly around axis10′ with respect to stator by a key engagement (not shown) existingbetween member 23 and stator 10. As a result, member 22 will bereferenced angularly around axis 10′ with respect to stator 10. Thischain of referencing achieves that the leads coming from the statorslots will result referenced with respect to routing surfaces of members22 and 23.

When requiring to route and twist the leads, members 22 and 23 can belocked to stator 10 by means of assembly 50 (see FIGS. 4, 4 a, 4 b and 4c). The same assembly will lock stator 10 to an appropriate seat of astation as will become more apparent in the following.

Member 22 can be locked to the stator by means of shaft 51, which hasenlarged end 51′ that presses on shelf 58 of member 22 when shaft 51 ispulled in direction 52′ (parallel to axis 10′) by linear actuator 53.

Similarly, member 23 can be locked by means of tube 55, which hasenlarged end 55′ that presses on shelf 59 of member 23 when tube 55 ispulled in direction 52′ by linear actuator 56.

Member 22 can move in direction 52 and 52′ with respect to member 23 dueto the sleeve assembly existing in cavity 25. Pin 70 which can abutagainst shelves 71 and 72 of member 23 limits the movement of member 22with respect to member 23. In addition, pin 70 can act as a pressingconnection between member 22 and 23. In fact, locking of members 22 and23 to stator 10 can be accomplished by pressing with enlarged end 51′ onshelf 58 and with enlarged end 55′ on shelf 59, i.e. in direction 52′.As a result, pin 70 can press on shelf 71 whilst cylindrical shoulder 24of member 23 presses on face 15 to lock members 23 to the stator.Consequently member 22 becomes locked to the stator through pressing ofpin 70 on shelf 71.

Linear actuator 53 is connected to shaft 51 by means of coupling 54,which allows rotation around axis 10′. Similarly, linear actuator 56 isconnected to tube 55 by means of coupling arm 57, which allows rotationaround axis 10′ due to bearing 57′ assembled between tube 55 andcoupling arm 57.

Shaft 51 can be rotated around axis 10′ to orient enlarged head 51′ withrespect to passage 60 of member 22 in order to lock member 22. In theposition of FIG. 4 a, enlarged head 51′ is pressing on shelf 58 andtherefore is oriented at 90 degrees with respect to axis 60′. To passenlarged head 51′ through passage 60 in order to remove members 22 fromthe stator, shaft 51 needs to be rotated 90 degrees to align at zerodegrees enlarged head 51′ with axis 60′. In this way, the ellipticalform of head 51′ will be able to pass through the corresponding form ofpassage 60.

Similarly, enlarged head 55′ of tube 55 has an elliptical form thatneeds to pass through a corresponding form of passage 61. Tube 55 can berotated around axis 10′ to orient enlarged head 55′ with respect topassage 61 of member 23. In the position of FIG. 4 b, enlarged head 55′is pressing on shelf 59 and therefore is oriented at 90 degrees withrespect axis 61′. To pass enlarged head 55′ through passage 61 in orderto remove members 23 from the stator, tube 55 needs to be rotated 90degrees to align at zero degrees enlarged head 55′ with axis 61′.

Rotation of shaft 51 around axis 10′ to orient enlarged head 51′ can beaccomplished using assembly 62, which consists of linear actuator 63that is able to translate forward and backwards rack 64. Rack 64 mesheswith gear 65 assembled on shaft 51 and is capable of transmittingrotation through key 66. Key 66 is assembled on shaft 51 and is capableof running in a way of gear 65 when shaft 51 is moved in direction 52and 52′.

Similarly, rotation of tube 55 around axis 10′ to orient enlarged head55′ can be accomplished using assembly 67, which consists of linearactuator 68 that is able to translate forward and backwards rack 69.Rack 69 meshes with gear 69′ assembled on tube 55 and is capable oftransmitting rotation through key 69″. Key 69″ is assembled on shafttube 55 and is capable of running in a way of gear 69′ when tube 55 ismoved in direction 52 and 52′.

Therefore, enlarged heads 51′ and 55′ can be rotated between a positionwhich locks members 22 and 23 and a position which releases members 22and 23.

When members 22 and 23 are released they can be removed from stator 10by inserting gripper head 73 in bore 74 of member 22. Gripper head 73has expandable keys 73′ which can grip the inside surface of bore 74.Gripper head 73 also has abutment ring 73″ which can engage the uppersurface of member 22 to guarantee precise referencing between gripper 73and member 22. Member 22 is part of a transfer device 105 shown in FIG.14. Gripper 73 moves in direction 52 to remove members 22 and 23.Abutment of pin 72 against shelf 72 will guarantee that member 22carries with it member 23 when gripper 73 moves in direction 52(parallel to axis 10′) to remove members 22 and 23.

FIG. 4 c shows holder 80 which has groove 81 for seating stator 10 inalignment with axis 10′. Stator 10 can be kept pressed on the bottom ofgroove 81 by the pressure exerted with abutment surface 24 of member 23on face 15. Holder 80 can be assembled on a transfer table like isdescribed with reference to FIG. 14. Holder 80 becomes aligned withshaft 51 and tube 55 by movement of the transfer table

FIG. 4 c shows that members like 82 and 83 can be inserted in the freespace created between the bridges 92 of predetermined coils. Members 82and 83 can be supported in slots like 84 of holder 80 to achieve radialmotion (by means of an actuator—not shown) in order to become positionedas shown in FIG. 4 c. Furthermore, the support in the slots is needed tomake members 82 and 83 react when acting as support arms to resist thatthe coils become pulled in direction 52 during the operations to twistleads 16 and 17. In this way any tendency of the coils to move indirection 52 during the operations to twist the leads is avoided. Thestator can be placed on holder 80 by being moved in direction 52′ whileit centered with respect to the center of holder 80. In this way thestator becomes aligned also with shaft 51 and tube 55, which need tolock members 22 and 23.

FIGS. 2, 3 and 4 show the result of having grasped leads 16 and 17 withmanipulator 30 in the condition of the leads 12 being like is shown inFIG. 1 and having routed them as plural wires through slots 26 and 27and into seats 28 and 29 of member 22.

Member 22 can be moved in direction 52 to position it more distant fromstator 15 in order to create spacing 91 (see FIG. 6) for routing thewires around the stator. This can be accomplished by actuating actuator53 which moves enlarged head 51′ against elastic ring 90 to translatemember 22 in direction 52

Slots 26 and 27 are radial passages for the wire and present access fromthe periphery of member 22. Slots 26 and 27 communicate with seats 28and 29, respectively. Seats 28 and 29 can have the configuration ofbores, where each bore is able to receive at least the total section ofthe number of wires which need to form the twisted portion of a lead.

To grasp the leads and route them as has been shown in FIGS. 2, 3 and 4,manipulator 30 can move in directions X, Y and Z and accomplishrotations AO (see FIGS. 2 and 3) around axis Z. The mechanisms 111 (seeFIG. 14) for accomplishing these movements can be similar to theequipment that has been described in EP 469.426.

Manipulator 30 can draw the leads against surfaces 31 and 32 of member23 to route the plural wires along predetermined paths in order to reachlocations 18 and 19 where the bends occur. When the manipulator drawsthe wires W along these paths, the wires can run through the grippersection 30′ of the manipulator. The manipulator initially grips thewires W in the condition of leads 12 in FIG. 1. The grip can be at apoint along the wires that will allow the wires to run through thegripping section 30′ during routing.

Preferably wires W can be held by gripping section 30′ so that they donot cross as shown in FIG. 3. This result can be achieved by providinggripping section 30′ with respective seats for seating each of the wiresW. The seats can be grooves (hidden in FIG. 3 by the presence of wirepressing members 30″).

Due to the fact that wires W are seated in their respective seats of thegripping section 30′ during the movements of the manipulator 30, wires Wdo not cross each other when routed along the trajectories and wound inthe helixes of the twisted portions.

Surfaces 31 and 32 can be cylindrical sides respectively of portions 31′and 32′ of member 23 (see FIGS. 2 and 3), and can be located over coilends 14 (see also FIG. 4). As a result, the leads reach slots like 26and 27 by being routed along predetermined paths which follow thecontour of surfaces 31 and 32. Portions 31′ and 32′ can be received inrecesses of member 22 as shown for example in FIGS. 2 and 4.

At slots like 26 and 27, the manipulator draws the leads through theradial passage portions in order to locate the end portions of the leadswithin seats 28 and 29—see for example FIGS. 4 to 6

As illustrated in FIGS. 5 and 6, the manipulator can first move to drawthe plural wires against surfaces 31 and 32 and then into slots like 26and 27 to reach the required position in seats 28 and 29 and alignmentin predetermined directions 33 and 34.

A lead like 17 shown in FIG. 6 that is coming from two separate slots ofthe stator can be brought into slot 26 and seat 28 in two stages; i.e.in a first stage, lead portion 17 a can be brought into slot 26 and seat28 by manipulator 30. Successively, in a second stage, lead portion 17 bcan be brought into slot 26 and seat 28 by manipulator 30. Lead 17 isthus formed of two portions 17 a and 17 b. Both portions form bends at19 and pass in seat 28 to become directed in direction 34. The bends canbe formed by bending the plural wire against surface 22′, which islocated in the area adjacent to seat 28 and faces the stator

A lead like 16 shown in FIG. 5, which is coming from a single slot ofthe stator, can be brought into slot 27 and seat 29 in one stage ofgrasping and movement on behalf of manipulator 30. Lead 16 forms a bendat 18 and passes in seat 29 to become directed in direction 33. The bendcan be formed by bending the plural wires against surface 22′, which islocated in the area adjacent to seat 29 and faces the stator.

To start forming the twisted portions, the plural wires of leads like 16and 17 need to be held contemporarily by the manipulator respectively inpredetermined directions 33 or 34, with the plural wires constrained inthe positions of seats 28 and 29, see FIGS. 5 and 6. A pressing memberlike 93 (see FIG. 4) can press on the plural wires in their extents justoutside seats 28 and 29 to assure increased constraint of the pluralwires in seat 28 and 29. In FIG. 4, member 93 is pressing on the wiresin a radial direction 93′ towards axis 10′ of the stator.

Then to twist the leads (see FIGS. 7 and 8), manipulator 30 in thecondition of holding the plural wires as shown in FIGS. 5 and 6, rotatesaround its axis Z (rotation Al or AO) and at the same time rotatesaround axis Z′ (rotation A2), which is where the leads are positioned tobe in directions 33 or 34. To complete a turn of the various helixes onerotation around axis Z and a simultaneous rotation around axis Z′ isneeded.

In addition, manipulator 30 needs to move in direction 52′ to avoidexcessive strain on the wires as twisting progresses. This movement ofmanipulator 30 can be with a law of motion that maintains tension on thewires by pulling them against surface 22′. During this pull, wires W areprevented from moving towards the manipulator in direction 52 due totheir engagement against surface 22′. As a result, during thesemovements for twisting, the twisted portions will result in a preciselocation above the heads of the coils, due to the position constraintgiven by seats 28 and 29, and aligned in directions 33 and 34 due to thepull of manipulator 30.

Prior to starting rotation of the manipulator for twisting, terminationmember 22 can be moved in direction 52′, i.e. towards the core (seeFIGS. 7 and 8 showing member 22 nearer to the core). Contemporarily,manipulator 30 which is holding all the wires of the lead is moved indirection 52′ so that the wires do not become over strained due to themovement of member 22 in direction 52′. The movement in direction 52′ ofmember 22 will bring surface 22′ nearer to the coil heads 14 (see theconditions of FIGS. 7 and 8), which will later impede portions 16 a, 17a and 17 b from moving in opposite direction 52 during rotations of themanipulator to twist the leads. In addition, movement in direction 52′of member 22 compacts portions of leads like 17 a, 17 b and 16 a againstthe heads of the coils 14.

Correct twisting transforms the wires into a number of adjacent helixes,where each helix is formed from a wire (see FIGS. 7 and 8). The turns ofa helix correspond to the number of rotations accomplished bymanipulator 30. In addition the various helixes should be formedadjacent to each other without crossing, i.e. with turns of the samediameter D and with constant pitch, as shown in FIGS. 7 and 8. Imperfectforming of the helixes would cause disorderly winding of the helixes oneach other, thereby creating abnormal bulges and voids along the lengthof the twisted portions.

Rotations of the manipulator can be stopped when a predetermined numberof turns of the helixes have been formed. This can guarantee that apredetermined length of twisted portion exists from member 22 to cuttinglevel 37. At level 37, cutters 40 and 41 can approach each other indirections 40′ and 41′, respectively, to cut the twisted portions, asshown in FIG. 9.

If requiring to twist further portions of the leads remaining in seat 28and 29, then prior to cutting the twisted portions, termination member22 can be moved further in direction 52′ to cause the required leadportions to move in direction 52 in order to exit seats 28 and 29. Thenrotation of the manipulator can be resumed to continue twisting thewires up to the upper surface 22′″ of member 22.

When a high number of wires need to be twisted together, it can occurthat at least one wire remains untwisted at the center of the section ofthe twisted wires. To manage to twist even this wire, the wires can betwisted together in lower numbers, and successively the resultingtwisted portions can be twisted together to form a single twistedportion—see FIGS. 10-13 concerning operations for twisting a lead havingportions like 17 a and 17 b described in the foregoing.

As shown in FIGS. 10 and 11, a certain number of wires 42 of branch 17 aare brought into seat 28 and twisted together to form a first twistedportion 42 a. Successively, a further number of wires 42′ of branch 17 bare brought into seat 28 and twisted together to form a second twistedportion 42′a (see FIG. 12).

Then, as shown in FIGS. 12 and 13 the two twisted portions can begrasped by manipulator 30 and a resulting twisted portions 42 b can beformed by rotations A1 and A3. In this case rotation A3 can be aroundaxis Z′ located between the two twisted portions, as shown in FIGS. 12and 13.

FIG. 14 shows a layout of a rotating table transfer machine in which theprinciples of the invention can be applied. Transfer table 102 iscapable of rotating around center 201 in directions 201′. Holders like80 are fixed on the transfer table at positions like 202, 203, 204, 205,which are equidistant from each other for seating stators 10. Table 102stops rotation around center 201 to align the holders with manipulatorslike 30 present in each of stations A, B and C. Also present at eachstation of stations A, B and C is an assembly like 50 forlocking/unlocking members 22 and 23 as has been described in theforegoing with reference to FIG. 4. Furthermore at each of stations A, Band C a transfer arm 305 is capable of rotating around axis like 206.Each transfer arm 305 is provided with a gripper like 73 for applyingand removing members 22 and 23 from the stator positioned in the stationwhere the arm is located. Dashed lines 207 show a typical trajectorythat a gripper like 73 can accomplish to align members 22 and 23 withthe stators, prior to moving in direction 52′ to actually apply members22 and 23 to the stator. In each of stations A, B and C, a certainnumber of the total leads of a stator can be terminated according to thecycle principles that have been described in the foregoing for leads 16and 17. Therefore, in each of stations A. B and C a specific cycle ofthe three in sequence required to finish stator 10 will be accomplished.The sequence will start in station A and be finished in station C.Station DX can be a station for loading and unloading the stator betweenthe table and a conveyor (not shown).

At stations like A, B and C, members like 22 and 23 will be dedicatedfor the cycle to be accomplished, i.e. configured for predetermined leadtrajectories, and having seats like 28 and 29 and reference surfaceslike 22′ and 22″ positioned and configured specifically for the routing,bending and twisting that is required in the specific cycle of thestator. Station A. B and C can be operating at the same time so that astator can be processed in a fraction of the time that would be requiredfor an entirely sequential non parallel processing of the leads.

Control means 310 (see FIG. 14) can be programmed to move manipulators30 according to the variable lead trajectories that characterize thestator which needs to be processed. The control means causes themanipulator to perform the movements and tensioning cycle requiredduring the twisting processes mentioned in the foregoing

The programs foresee sequencing movements of member 22 in order tocompact the leads and function for twisting operations as has beenmentioned.

The same control means can sequence operations of table 102 and transferarms 305 to be synchronized with the operating cycle of manipulators 30.

Signal and supply lines will be available to connect the variousactuators to control means 310 as shown in FIGS. 4 and 14.

With reference to FIG. 16 a wound core 105 is shown positioned insupport assembly 100 of table 102 in preparation for routing andtwisting of the leads. In FIG. 16, the leads have been omitted forreasons of clarity. Coil heads 106 and 107 are shown adjacent torespective end faces 106′ and 107′ of the cores. Restraining memberslike 82 and 83 mentioned above with reference to FIG. 4C are referencedeither 103 or 104 in the embodiment of FIGS. 15 and 16

More particularly, in FIG. 16 portions of a first series of restrainingmembers 103 are shown positioned in the free spacing 131 existingbetween coil heads 106 and the adjacent face 106′ of the core 105. FIG.16 also illustrates a second series of restraining members 104 shown inthe free spacing existing between coil heads 107 and adjacent face 107′.The position of the restraining members illustrated in FIGS. 15 and 16is the radial inner most position of the restraining members towards thecentral axis 105′ of the core, and is required for supporting theportions of wires forming the coil heads during twisting. In thisposition the end portions of the restraining members prevent theportions of wires of the coils from moving towards the adjacent faces106′ and 107′ of the core when the leads of a coil are pulled by themanipulator during the twisting operations.

The outermost radial position (not shown) of the restraining members isa retracted position that allows core 105 to be inserted and positionedin the support assembly, like is shown in FIG. 16, by moving the core indirection DZ. More particularly, with the movement in direction DZ, core105 becomes positioned in the support assembly when face 107′ bearsagainst ridge 115″ of member 115, as is shown in FIG. 16. The core canbe oriented specifically around axis 105′, which is also the axis ofsymmetry of the support assembly, by engaging a protuberance (not shown)of member 112 in a slit of core 105. An automatic gripping device (notshown) of a load/unload unit present in station DX of FIG. 14 can beused for positioning and orienting the core in the support assembly bytranslation and rotation of the core, respectively in direction DZ andaround axis 105′.

Cover member 108 seats each restraining member 103 of the first seriesin a respective channel 121 placed along a radius that intersects axis105′ of the core (see also FIG. 15 where the cover portions 122 of thechannels are shown). The sides of each channel 121 guides a restrainingmember 103 along a respective radius during the alternative radialmovement between the coil head support position and the outermost radialposition.

Bottom member 109 is a disk member attached to cover member 108. Bottommember 109 acts as a support surface for the sliding movement ofrestraining members 103 during the radial movement.

A cam follower pin 103′ is assembled by means of a bolt on each ofrestraining members 103. The cam follower pin passes through arespective radial slot 109′ of bottom member 109 and finds seating andengagement in respective slots 110′ of driving member 110. More indetail, the engagement of the cam follower pin in slots 110′ can occuragainst a side of slot 110′.

Driving member 110 is seated and centered in containing member 111 forrotating around central axis 105′ of the core.

Containing member 111 is centered by support member 112. Containingmember 111 bears on spacer member 113, which is supported inside supportmember 112. Support member 112 is supported and fixed on the surface oftable 102 by means of fixing plates 120.

The height H of spacer member 113 determines the height of restrainingmembers 103 from ridge 115″ where the core to be processed is supported.By substituting spacer member 113 with a spacer member 113 of differentheight, different positions of restraining members 103 can be reached tocompensate for differences in the height of the cores that need to beprocessed.

Slots 110′ are present for each cam follower pin 103′ and have anextension in a plane perpendicular to axis 105′ (see FIG. 15 for thedashed line representation of the extension of the slots), which makesthe side of slots 110′ engaged by cam follower pin 103′ produce a radialmotion of a restraining member 103 when driving member 110 is rotatedaround axis 105′ in direction R. Therefore, rotation in direction Raround axis 105′ will cause synchronized inward radial movement of allthe restraining members 103, whilst rotation in opposite direction R′around axis 105′ will cause synchronized outward radial movement of allthe restraining members 103.

A first series of bolts (not shown) have their heads pressing againstmember 108 and are screwed into member 111. The stems of these boltspass through openings of members 109 and 110. Accordingly member 108 isjoined to member 111. Members 103 and drive member 110 are packed inbetween members 108 and 111 and are able to accomplish their respectivemovements due to an adequate play that is typically foreseen betweenstationary and moving parts.

A second series of bolts 130 (the heads of which are shown in FIG. 15,whilst one of the axes of their stems is shown in FIG. 16) have headspressing against member 111 and are screwed into member 112.Accordingly, member 111 is joined to member 112. Therefore member 108becomes joined to member 112 because member 108 is joined to member 111by means of the first series of bolts.

This arrangement makes it possible to provide the support assembly 100only with a first series of restraining members 103 for supporting thecoils heads, i.e. without the second series of restraining members 104,if required.

When the second series of retraining members are foreseen, eachrestraining members 104 of the second series can be seated in arespective radial channel 115″ of member 115. The radial channel 115′guides the restraining member during the radial movement to reach thecoil head support position shown in FIGS. 15 and 16.

Member 115 is fixed to support member 112 by bolts (not shown). Member114 is interposed between member 115 and support member 112, and acts asa running surface for restraining members 104 when restraining members104 move in the radial directions.

A cam follower pin 104′, like 103′, is assembled by means of a bolt oneach of restraining members 104. The cam follower pin 104′ passesthrough a respective radial slot of bottom member 115 and finds seatingand engagement in respective slots 116′ of second driving member 116.The engagement of a cam follower pin 104′ in a respective slot 116′occurs against a side of slot 116′.

Driving member 116 is assembled on the outer ring of bearing 119. Theinner ring of bearing is assembled in a seat of member 115. Cap 117 isfixed by bolts (shown with the dashed line 117′) to member 115 in orderto secure the inner ring of bearing 119 to member 115. Similarly, cap118 is fixed by bolts (shown with the dashed line 118′) to member 116 inorder to secure the outer ring of bearing 119 to member 116.

Slots 116′ have an extension in the plane perpendicular to axis 105′that is identical to the extension of slots 110′ in their previouslymentioned parallel plane. Therefore, cam follower pin 104′ engages aside of slots 116′ to produce a radial motion of a restraining member104 when driving member 116 is rotated around axis 105′ in direction R.Therefore, rotation in direction R around axis 105′ will cause inwardsynchronized radial movement of all the restraining members 104, whilstrotation in opposite direction R′ around axis 105′ will cause outwardsynchronized radial movement of all the restraining members 104.

The assembly of bottom member 115 to support member 112 and the assemblyof drive member 116 to bottom member 115 is an arrangement that allowsthe support assembly to be provided only with the second series ofrestraining members 104, i.e. without the first series of restrainingmembers 103, if required.

Driving member 110 is provided with an arm portion 123 that extendsoutwardly from the support assembly through a slotted portions of member111. Similarly, second driving member 116 is provided with arm portion124 that extends outwardly from the support assembly. A cylindrical bushmember 125 can be interposed between arm portion 123 and arm portion 124by being assembled on the stem of bolt 126. Bolt 126 passes though boresof arm portions 123 and 124.

Arm 129 of an actuating unit 128 (see FIG. 15) can rotate around fulcrum127 in either directions of rotation Q or Q′ to engage and push on bushmember 125. Accordingly, arm portion 123 and arm portion 124 will berotated in direction R or R′ respectively by rotation Q or Q′ of arm 129around fulcrum 127 to produce the required radial motions of restrainingmembers 103 and 104.

It should be contemplated that arm portion 123 by itself can be rotatedby an arm like 129 when only the first series of restraining members 103are present in the support assembly. Similarly, arm portion 124 byitself can be rotated by an arm like 129 when only the second series ofrestraining members 104 are present in the support assembly.

Removal of support assembly 100 from the table and its substitution withanother support assembly can occur by removing bolts 130 that fix member111 to support member 112 and by releasing bolt 126. In this way member108, the series of restraining members 103, member 109, driving member110 and member 111 can be removed as a unit from table 102.

Furthermore, removal of plates 120 from engagement with the slots ofsupport member 112 allows support member 112, member 114, member 115,the series of restraining members 104 and member 116 to be removed as aunit from the underside of the table 102, by movement of support member112 in direction DZ.

The foregoing is merely illustrative of the principles of this inventionand various modifications can be made by those skilled in the artwithout departing from the scope and spirit of the invention.

The invention claimed is:
 1. A method for terminating leads of coils ofdynamo electric machine cores, each respective lead being formed fromrespective plural wires, the method comprising: manipulating the pluralwires of a respective one of the leads to dispose the plural wires ofthe respective one of the leads along a respective predeterminedtrajectory in relation to a core of the dynamo electric machine cores;receiving the plural wires of the respective one of the leads in arespective seat positioned in a respective predetermined location alongthe respective trajectory; bending the plural wires of the respectiveone of the leads adjacent an entrance of the respective seat forredirecting the wires along a respective predetermined directionextending from the respective predetermined location; holding a firstlength of the plural wires of the respective one of the leads extendingbeyond the respective seat in the respective predetermined direction;rotating the first length to twist the plural wires of the respectiveone of the leads being held along the respective predetermineddirection; and translating the first length being held to maintain apull on a further portion of the plural wires of the respective one ofthe leads against a respective reference surface adjacent an entrance ofthe respective seat during twisting of the plural wires of therespective one of the leads.
 2. The method of claim 1 further comprisingrouting the plural wires of the respective one of the leads along arespective second reference surface to dispose the plural wires of therespective one of the leads along the respective predeterminedtrajectory prior to directing the plural wires of the respective one ofthe leads in the predetermined direction.
 3. The method of claim 1further comprising temporarily locating the respective seat atpredetermined angular and radial distances with respect to a centralaxis of the core.
 4. The method of claim 1 further comprising moving therespective reference surface towards the core prior to starting twistingof the plural wires of the respective one of the leads.
 5. The method ofclaim 4 further comprising after twisting a length portion of the pluralwires of the respective one of the leads, moving the reference surfaceaway from said core to twist a further length portion of the pluralwires of the respective one of the leads.
 6. The method of claim 1further comprising receiving a first subset of plural wires of therespective one of the leads in the respective seat and twisting thefirst subset of plural wires together.
 7. The method of claim 6 furthercomprising receiving a second subset of plural wires of the respectiveone of the leads in the respective seat and twisting the second subsetof plural wires together; and successively twisting the first subset andthe second subset together.
 8. The method of claim 1 further comprisingshearing a twisted portion of the plural wires of the respective one ofthe leads extending in the respective predetermined direction.
 9. Themethod of claim 1 further comprising supporting respective bridges ofthe coils towards faces of the core during twisting of the plural wiresof the respective one of the leads.